Mutualistic engine controller having sensor communication

ABSTRACT

A printing device includes at least one printing engine that has many sensors (first sensors and second sensors) and at least one engine controller operatively connected to the printing engine. The engine controller uses software to control operations of the printing engine. Also, at least one non-volatile memory is operatively connected to the engine controller. The non-volatile memory stores values used by the engine controller to control operations of the printing engine. At least one adapter card is operatively connected to the non-volatile memory and to the first sensors and second sensors. The first sensors correspond to the design of the controller and are items designed as original equipment of the printing device. To the contrary, the second sensors correspond to the design of the adapter card and are items designed to be installed in the printing device after the printing device is in post production, customer service. The adapter card receives feedback from the first sensors and the second sensors and the adapter card reads and modifies incoming print jobs before the print jobs are delivered to the controller.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is related to the following co-pending applicationsfiled concurrently herewith by the same Applicants and assigned to thesame Assignee: “MUTUALISTIC ENGINE CONTROLLER HAVING CUSTOMERREPLACEABLE UNIT COMMUNICATION,” Ser. No. 12/730,512, and “MUTUALISTICENGINE CONTROLLER UNIT COMMUNICATING WITH PRINTER NON-VOLATILE MEMORY,”Ser. No. 12/730,633. The complete disclosures of these co-pendingapplications are incorporated herein by reference.

BACKGROUND AND SUMMARY

Embodiments herein generally relate to electrophotographic printers andcopiers or reproduction machines, and more particularly, concerns anadapter card that can communicate with sensors within the printer.

Many recent advances in printing focus on better integration of controlsystems with the hardware and materials to improve run cost and otherfunctionally important topics (FITs). Many of the concepts and proposalsbeing developed require some level of software integration to gain thefull run cost or other FIT benefits. While there is some input to thecontrol software for a manufacturer's developed products, for outsourcedor acquired products, the “hooks” into the software to implementadvanced technology concepts are lacking, and getting outsource vendorsto provide the appropriate taps into the machine control is sometimesdifficult. Some of these concepts could benefit the current machinepopulation in the field greatly, but would require a costly and nearlyunfeasible software upgrade to implement. In such instances, amanufacturer would likely have very little control of the systemsoftware, but would want to inject value-add technologies to improve theperformance and robustness of these base engines.

This disclosure outlines a method of obtaining the required control“hooks” in an outsourced print controller that enables concepts beingdeveloped to improve run cost and other FITs in current and futureacquired engines. Most print engines support some form of externalupdates of their non-volatile memory (NVM)—through a front panel userinterface, service interface, TCP/IP connection, print job submissioninterface, etc. By adding a low cost electronic module to the enginethat communicates with the customer replaceable unit memory, oftenthrough RFID interface, and the machine control unit (MCU), embodimentsherein use an image path actuation or other actuators within themachine. In addition, they may require inputs that are outside the scopeof just NMV.

Embodiments herein take advantage of the standard interfaces normallyprovided by the machine control unit to enable implementation oftechnology concepts without requiring changes to the system software ofthe engine. In addition, the embodiments herein enable manufacturing tomodify machine settings on a cartridge by cartridge basis to enableimprovements that are developed during the machine's life cycle, withoutrequiring a service engineer to make any software upgrades orunscheduled maintenance, and without requiring any special “hooks”within the machine's engine control software.

More specifically, embodiments herein comprise a printing device thatincludes at least one printing engine that has many sensors (firstsensors and second sensors) and at least one engine controlleroperatively connected to the printing engine. The engine controller usessoftware to control operations of the printing engine. Also, at leastone non-volatile memory is operatively connected to the enginecontroller. The non-volatile memory stores values used by the enginecontroller to control operations of the printing engine.

With embodiments herein at least one adapter card is operativelyconnected to the non-volatile memory and to the first sensors and secondsensors. The first sensors correspond to the design of the controllerand are items designed as original equipment of the printing device. Tothe contrary, the second sensors correspond to the design of the adaptercard and are items designed to be installed in the printing device afterthe printing device is in post production, customer service.

The adapter card receives feedback from the first sensors and the secondsensors and the adapter card reads and modifies incoming print jobsbefore the print jobs are delivered to the controller.

In another embodiment, the printing device comprises at least oneprinting engine that has actuators, first sensors, and second sensors.In this embodiment, the adapter card is operatively connected to thenon-volatile memory, the actuators, the first sensors, and the secondsensors. The first sensors and the actuators correspond to the design ofthe controller and comprise items designed as original equipment of theprinting device, while the second sensors correspond to the design ofthe adapter card and comprise items designed to be installed in theprinting device after the printing device is in post production,customer service.

In this embodiment, the adapter card stores data and receives sensorfeedback from the second sensors, the adapter card uses the data and thesensor feedback to control the actuators by bypassing the enginecontroller when communicating with the actuators. The adapter cardprovides adapter card feedback to the non-volatile memory.

The adapter card comprises a physically separate device from the enginecontroller. More specifically, the adapter card can comprise, forexample, a printed circuit board, at least one logic unit mounted on theprinted circuit board, wiring within the printed circuit board connectedto the logic unit, and connection terminals on the printed circuit boardconnected to the wiring. The connection terminals can be operativelyconnected to the non-volatile memory.

The adapter card can be connected to the non-volatile memory through oneof the following interfaces: TCP/IP based web server interface; frontpanel keyboard wedge interface; service interface; direct hardwiredconnection; etc. Further, the adapter card comprises an item designed tobe installed in the printing device after the printing device is in postproduction, customer service. This also covers the case of sourcing athird party engine, then adding the adapter card to enable delivery ofvalue-add solutions without the update of the existing engine controlleror system software.

These and other features are described in, or are apparent from, thefollowing detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

Various exemplary embodiments of the systems and methods are describedin detail below, with reference to the attached drawing figures, inwhich:

FIG. 1 is a schematic diagram of a printing device according toembodiments herein;

FIG. 2 is a schematic diagram of an adapter card according toembodiments herein;

FIG. 3 is a flow diagram illustrating method embodiments herein;

FIG. 4 is a flow diagram illustrating method embodiments herein;

FIG. 5 is a flow diagram illustrating method embodiments herein;

FIG. 6 is a schematic diagram of a printing device according toembodiments herein;

FIG. 7 is a schematic diagram of a printing device according toembodiments herein;

FIG. 8 is a schematic diagram of a printing device according toembodiments herein;

FIG. 9 is a schematic diagram of a printing device according toembodiments herein;

FIG. 10 is a schematic diagram of a printing device according toembodiments herein;

FIG. 11 is a schematic diagram of a printing device according toembodiments herein;

FIG. 12 is a schematic diagram of a printing device according toembodiments herein; and

FIG. 13 is a schematic diagram of a printing device according toembodiments herein.

DETAILED DESCRIPTION

Referring now to FIG. 1, embodiments herein include a printing device200 that has at least one printing engine 210 that is at least partiallymade up of customer replaceable units (CRU) 212/214. The customerreplaceable units or modules 212/214 can comprise, for example,photoreceptors, fusers, drums, rollers, toner cartridges, inkcartridges, etc., and are items that are usually replaced by either acustomer or an end user (and do not require the services of a trainedservice technician). Customer replaceable units are items that arewell-known to those ordinarily skilled in the art (for example, see U.S.Pat. Nos. 7,146,112 and 7,529,491, the complete disclosures of which areincorporated herein by reference) and are available from manufacturerssuch as Xerox Corp., Norwalk Conn., USA. Therefore, a detaileddiscussion of such customer replaceable units is not included herein soas to focus the reader on the salient features of the disclosedembodiments.

At least one engine controller 216 is operatively connected to theprinting engine 210. The engine controller 216 uses software,potentially stored in a memory device (magnetic storage medium, etc.)222, to control the operations of the printing engine 210. Enginecontrollers and printing devices are items that are well-known to thoseordinarily skilled in the art (for example, see U.S. Pat. No. 7,237,771the complete disclosure of which is incorporated herein by reference)and are available from manufacturers such as Xerox Corp., Norwalk Conn.,USA. Therefore, a detailed discussion of such items is not includedherein so as to focus the reader on the salient features of thedisclosed embodiments.

In addition, the printing device 200 includes an interface or digitalfront end (DFE) 208 that can comprise a scanner, a graphic userinterface, network connections, TCP/IP serial communication, front panelkeyboard, or direct connection, and/or other input output connections.Incoming print jobs are sent to the engine via the interface 208. Theinterface 208 raster image processes (RIPS) the job and sends it to theengine controller 216 to be imaged onto the photoreceptor (212/214),transferred, and finally fused to the sheets of media (substrate). Theprinting device 200 draws sheets of media from the sheet supply 202 andutilizes a paper path 204 to feed the sheets through the printing engine210. A finisher unit 206 can process the sheets after they have beenprinted by stapling, binding, folding, etc., the sheets.

At least one non-volatile memory 218 is operatively connected to theengine controller 216. The non-volatile memory 218 stores values used bythe engine controller 216 to control operations of the printing engine210. At least one adapter card 220 is operatively connected to thenon-volatile memory 218 and to the customer replaceable units 212/214.The lines between the units shown in FIG. 1 can comprise wires orwireless connections, such as radio frequency identification (RFID)wireless communication connections. The adapter card 220 is shown ingreater detail in FIG. 2 and comprises a physically separate device fromthe engine controller 216.

Referring to FIG. 2, the adapter card 220 comprises a separate printedcircuit board 230 and at least one processor or logic unit 232 mountedon the printed circuit board 230. A memory unit 234 can also be attachedto the printed circuit board 230. Wiring is present within the printedcircuit board 230 and is connected to the processor 232 and memory 234.Connection terminals 236 on the printed circuit board 230 are connectedto the wiring. As would be understood by those ordinarily skilled in theart, other items such as electrostatic discharge circuitry, variouscapacitors, resistors, etc., would be included within the adapter card220; however, such structures are intentionally not illustrated in FIG.2 in order to simplify the drawings.

The connection terminals 236 connect to corresponding connectionterminals 238 of the printing device. The printing device connectionterminals 238 are connected to the wiring within the printing device200. Therefore, the adapter card connection terminals 236 areoperatively (indirectly) or directly connected to the non-volatilememory 218 and to the customer replaceable units 212/214.

For example, the printing device connection terminals 238 can be wiredinto the printing device standard service interface 240 that serviceengineers connect to when reprogramming the values within thenon-volatile memory 218. This allows the adapter card 220 to perform thesame activities that could be performed by a service engineer, withoutrequiring a service call. The printing device standard service interface240 could be, in some embodiments, part of the interface 208 illustratedin FIG. 1, or could be a separate structure.

Alternatively, the printing device connection terminals 238 could bedirectly wired to the non-volatile memory 218 or could be wired to theany other access point or controller that would allow access to thenon-volatile memory 218. Further, the printing device connectionterminals 238 are connected to the systems within the printing device200 that read and maintain the data from the customer replaceable unit'smemory 212/214. (For details regarding such systems, see the previouslymentioned U.S. Pat. No. 7,146,112).

At least one of the customer replaceable units (CRU) 212/214 has amemory unit (customer replaceable units 212) that stores information anddata used by the machine (date produced, origin, country, etc.) andinformation that is recorded from the machine (machine print counts,paper sizes printed, pixel counts, etc.) that help the printing engine210 operate properly, often through an RFID interface. The non-volatilememory 218, the memory units within the customer replaceable units212/214, and the memory unit 234 can comprise any type of computerreadable storage medium including a non-volatile memory, random accessmemory, a permanent storage medium (magnetic, optical, etc.).

The data maintained within the memory of the customer replaceable units212/214 changes as the design of the customer replaceable units 212/214are updated and improved over time. This data and information may bedifferent than the information that was available when the printingdevice 200 was originally manufactured. Therefore, when a customerreplaces one of the customer replaceable units 212/214, the customer notonly replaces a consumed or worn out component, the customer alsoupdates the information provided to the printing device 200 to help itcontinue to operate at peak performance and fully utilized the designupdates and advances that may have been made to the customer replaceableunits 212/214.

Some of the updates included within the memory of the customerreplaceable units 212/214 can require changes to the non-volatile memory218; however, if the customer replaceable units 212/214 are manufacturedby a different organization than the manufacturer of the printing device200 and/or the manufacturer of the engine controller 216, theinformation within the customer replaceable unit may be in anincompatible format for the controller 216 to utilize. Therefore, theadapter card 220 is configured to bypass the controller 216 and directlyalter the non-volatile memory 218. This allows the adapter card 220 toalter the non-volatile memory 218 without having to alter the softwareused by the engine controller 216 and without requiring the expertise ofa trained service engineer.

The adapter card 220 reads data from the memory unit that resides withthe customer replaceable unit. The adapter card 220 uses the data todirectly alter values within the non-volatile memory 218 (even if thesoftware used by the engine controller 216 is non-compatible with thedata within the memory unit) by bypassing the engine controller 216 whencommunicating with the non-volatile memory 218.

As shown in flowchart form in FIG. 3, one exemplary manufacturing methodembodiment herein begins in item 300 by supplying the aforementionedprinting engine 210 that has the customer replaceable units 212/214. Initem 302, the method connects the engine controller 216 to the printingengine 210 and, in item 304, connects the non-volatile memory 218 to theengine controller 216. In item 306, the method also connects the adaptercard 220 to the non-volatile memory 218 and to the customer replaceableunits 212/214.

As shown in flowchart form in FIG. 4, in an operational example,according to one method herein (in item 400) the adapter card 220 readsdata from the memory unit within one of the customer replaceable units212/214, and in item 402 the adapter card 220 uses the data to directlyalter values within the non-volatile memory 218 by bypassing the enginecontroller 216 when communicating with the non-volatile memory 218.

FIG. 5 illustrates, in flowchart form, that the method embodimentsherein further comprise a manufacturing method for the adapter card 220.This process comprising providing the printed circuit board 230 (item500); mounting at least one processor 232 on the printed circuit board230 (item 502); connecting the wiring within the printed circuit board230 to the processor 232 (item 504); and connecting the connectionterminals 236 on the printed circuit board 230 to the wiring (item 506).

As shown in FIG. 6, additional embodiments herein comprise a portion ofthe printing device 200 that includes at least one printing engine 210that has many sensors (first sensors 254, second sensors 256, etc.). Thesensors can comprise existing sensors 254 that are original equipment ofthe printing device 200 and additional sensors 256 that are added to theprinting device 200 after the printing device 200 has been post-originalmanufactured. The first sensors 254 correspond to the design of thecontroller 216 and are items designed as original equipment of theprinting device. To the contrary, the second sensors 256 correspond tothe design of the adapter card and are items designed to be installed inthe printing device after the printing device is in post production,customer service. For example, the additional sensors 256 can be addedat the same time that the adapter card 220 is added to the post-originalmanufactured printing device 200. These items could be installed in theprinting device 200 even after the printing device 200 has been inservice in the field for an extended period of time.

In these embodiments also, at least one engine controller 216 isoperatively connected to the printing engine 210. Again, the enginecontroller 216 uses software to control operations of the printingengine 210. At least one non-volatile memory 218 is again operativelyconnected to the engine controller 216. The non-volatile memory 218stores values used by the engine controller 216 to control operations ofthe printing engine 210.

Note that in FIG. 6, and the other drawings, not all connections areshown to avoid clutter in the drawings. For example, connections betweenthe controller 216, the actuators 252, 254, the customer replaceableunits 212, etc., are shown by a single connection line to avoid clutter.Similarly, connections to the non-volatile memory 218, system software,digital front end, engine controller 242, etc., are understood to beincluded within the single major component lines illustrated. In otherwords, it would be understood by one ordinarily skilled in the art thatthe existing actuators 252, existing sensors 254, customer replaceableunits 212, etc., are connected to the existing system controller 216 andsuch individual connections are not illustrated in the drawings to avoidclutter.

With embodiments herein at least one adapter card 220 is operativelyconnected to the non-volatile memory 218 and to the first sensors 254and second sensors 256. The adapter card 220 receives feedback from thefirst sensors 254 and the second sensors 256 and the adapter card 220reads and modifies incoming print jobs from the print job stream 260before the print jobs are delivered to the controller 216. Therefore, inthe embodiment shown in FIG. 6, the incoming job stream from the printjob stream 260 is intercepted and altered by the adapter card 220depending upon the readings from the existing sensors 254 and theadditional sensors 256. Then, the adapter card 220 outputs a modifiedjob stream to the controller 216, which executes the modified job streamto complete each print job.

An example of the use of such an embodiment is as follows. The adaptercard 220 submits a streak calibration print job. A full width arraysensor within the engine can measure the streaks on the streakcalibration prints. The adapter card 220 then processes the streakcalibration data and produces a streak compensation. Following this, acustomer print job can be submitted. As mentioned above, the adaptercard 220 intercepts the print job and applies the streak compensation tothe print job. The adapter card 220 then provides the modified print jobto the print engine and the print job is produced. Other similar controlloops are possible using the adapter card 220 (tone reproduction curvecontrol, banding compensation, ghosting, halo, etc.) depending on thesensor involved and the characteristics of the defect. Using theembodiment shown herein, the original equipment manufacturer (OEM) printengine system software does not need to be modified, nor does the OEMprint engine system software need to inherently support the desiredsensor data analysis and image compensation processing.

The additional sensors 256 capture information that was not contemplatedfor use according to the design of the existing system controller 216,but the additional sensors 256 capture data that is used by the adaptercard 220. For example, it may be found that with additional informationfrom new areas of the printing engine 210, the performance of theprinting engine 210 may be improved. Therefore, the adapter card 220 (incombination with the added sensors 256) allows the existing systemcontroller 216 to achieve higher performance levels by measuring andacting on newly acquired data and information that was not considerednecessary (that was not needed) when the existing system controller 216was designed and manufactured.

Further, the additional sensors 256 can correspond to the updated designof newly manufactured customer replaceable units 212. For example, thecustomer replaceable units 212 may have a new design or use newmaterials that were developed after the original equipment customerreplaceable units (and the existing system controller 216) were designedand manufactured (or that are different than the original equipmentmanufacturer's design). Such newly manufactured/designed customerreplaceable units may increase the performance of the printing engine210, but may need different control instructions from the controller.Therefore, the additional sensors 256 can be specifically designed toobtain information that relates to maximizing the performance of the newor different designs of the customer replaceable units.

Thus, the incoming job stream from the print job stream 260 isintercepted and altered by the adapter card 220 depending upon thereading from the existing sensors 254 and the additional sensors 256 totake advantage of new or different designs/materials that newly designedcomponents 212 may offer, so as to improve the performance of theprinting engine 210.

In another embodiment, shown in FIG. 7, the adapter card 220 stores dataand receives sensor feedback from the second sensors 256, the adaptercard 220 uses the data and the sensor feedback to control the actuatorsby bypassing the engine controller 216 when communicating with theactuators. The adapter card 220 can also receive sensor data from theexisting sensors 254. Further, the adapter card 220 provides adaptercard 220 feedback to the non-volatile memory 218.

Thus, in the embodiment shown in FIG. 7, the adapter card can replace orpartially replace the functions of the existing system controller 216 byreceiving at least a copy of the incoming print jobs from the print jobstream 260, interacting with the non-volatile memory 218, and alteringthe settings of the existing actuators 252 within the printing engine210. When interacting with the existing actuators 252, the adapter card220 can provide settings to the actuators that are not necessarilyconsistent with the settings that the existing system controller 216would provide; however, such new settings provided by the adapter card220 can improve the performance of the printing engine 210. This allowsthe adapter card 220 to utilize advances that may have occurred afterthe existing system controller 216 was designed and that may only beavailable because of the additional information provided by theadditional sensors 256.

Thus, the embodiment shown in FIG. 7 enables deployment of newtechnologies to the field for improved machine performance with noupgrade of the system software required. In addition, there is nospecial requirement on the system software to support this upgradefunctionality. Most engines already support adjustment of thenon-volatile memory settings through at least one interface with theexternal world. The present invention places a smart box (the adaptercard 220) within the engine to enable such non-volatile memory upgrades.The system software does not need to be changed at all to enable theadapter card 220.

The adapter card 220 provides a feasible path for retrofitting newadditional sensors into existing engines to enable significant upgradesin engine performance. Without the adapter card 220, implementation ofengine control changes requiring new additional sensors have proven tobe very difficult. Thus, the adapter card 220 removes this barrier toimproved engine performance.

In another embodiment, shown in FIG. 8, the adapter card 220 readsincoming print jobs before the print jobs are delivered to thecontroller 216 and the adapter card 220 accumulates and storesstatistics relating to print jobs within the memory 218 unit of thecustomer replaceable units. The statistics can comprise, for example,area coverage on a page-by-page basis, localized pixel counts (in bothdimensions), maximum number of layers used per page, area coveragespread (concentrated in one region versus across the entire page) perpage, media type, job lengths, machine usage as a function of time ofday, etc. In the embodiment shown in FIG. 8, the adapter card 220 passesthe incoming print jobs to the controller 216 in an unaltered manner.

As is known by those ordinarily skilled in the art, the customerreplaceable units 212 are typically returned to the manufacturer forrefurbishing (are recycled). During such refurbishing, with theembodiment shown in FIG. 8, the various statistics can be downloadedfrom the memory within the customer replaceable units 212. This allowsthe manufacturer to utilize the statistics to understand the customerusage of the printing device 200, which allows the manufacturer toimprove the performance of the customer replaceable unit and of theprinting device itself. Such statistics can also help the manufacturercreate new designs that may be more appropriate considering the actualtypes of print jobs that are being processed through the printing device200.

The embodiment shown in FIG. 8 is minimally intrusive but dramaticallyenhances the manufacturer's capability to obtain extended informationabout customer usage, without requiring changes to the existing systemsoftware to do so. While data logging via network connections can obtainsimilar information, such network solutions are not always well receivedby many customers due to security concerns. This embodiment provides ameans of acquiring the same data, without any customer intervention orapproval requirements.

The data storage capacity of the customer replaceable units maysometimes be limited. Therefore, the image/job analysis performed by theadapter card 220 reduces the data to key information (usage counters,etc), rather than storing the entire job stream of images. In addition,the adapter card 220 enables customer replaceable units 212 data loggingof information that may not have been foreseen at print engine designtime. For example, a newly developed (after print engine launch)customer replaceable unit may include a new cleaning blade. Engineersmay desire customer replaceable units 212 data logging of a counter for:minimum pixel count in cross-process direction, which is a newrequirement, unforeseen when the print engine with its original customerreplaceable units was developed. Without the adapter card 220 a newprint engine system software version would be required, which can takesignificant time, effort, and cost. Thus, the embodiment shown in FIG. 8enhances the value add path for technology injections through advancedcustomer replaceable units, some of which many even be implemented afterprinter engines are in the field. The ability to add capabilityunforeseen at design time is one benefit provided by the embodimentsherein.

FIG. 9 illustrates an additional embodiment. As mentioned above, thenon-volatile memory 218 stores values used by the engine controller 216to control operations of the printing engine 210. In the embodimentshown in FIG. 9, the adapter card 220 reads these values from thenon-volatile memory 218 and the adapter card 220 stores the valueswithin the memory unit of the customer replaceable units 212. Then, whenthe customer replaceable units 212 are refurbished by the manufacturer,the values within the non-volatile memory 218 can be utilized to improvethe printing operations of the printing device 200.

In the embodiment shown in FIG. 9, the adapter card 220 module readsvarious non-volatile memory 218 locations, at a selectable interval, andwrites this information to one (or several) of the customer replaceableunits 212 in the printer. This information can then be used during thepost-mortem analysis of these replaceable components to betterunderstand how the printer is performing over time and how sensing andactuator values are changing within the printer under actual customeroperating conditions. The types of information that are captured includethe daily print count, process control patch densities, charge gridvoltage, electrostatic voltmeter readings, toner concentration (TC)setpoints, temperature and relative humidity (RH) readings, etc. Thisinformation can be post-processed from the customer replaceable units212 and used to provide engineering teams extremely useful informationto help develop improved products or enhance current ones. The adaptercard 220 module can be added before the machine is delivered to thecustomer or even after delivery, as a field upgrade kit, providing amethod to read and record important non-volatile memory 218 locationsover the machine's life without any service engineer intervention.

The type of information that can be gathered by the adapter card 220 isillustrated in the following examples. For example, the adapter card 220can write daily print counts into customer replaceable units 212 toprovide a breakdown throughout the month of customer job distributions(daily load). In addition, the adapter card can periodically read printcount and density sensor patch readings from non-volatile memory 218 andlog such information to the customer replaceable units 212. This gives atime history (though incomplete) of the mass sensor data that is nottypically available. Also, the adapter card can periodically read printcount and temperature and RH sensor readings from non-volatile memory218 and log the same to the customer replaceable units 212. This gives atime history (though incomplete) of the environmental sensor data thatis not typically available.

In a different embodiment, shown in FIG. 10, the non-volatile memory 218stores values used by the engine controller 216 to control operations ofthe printing engine 210 and the adapter card 220 also stores new data.The adapter card 220 uses the new data to alter the values within thenon-volatile memory 218 by bypassing the engine controller 216 whencommunicating with the non-volatile memory 218. This allows the adaptercard 220 to alter the values within the non-volatile memory 218according to conditions that are observed by the adapter card 220 whenit reads information from the non-volatile memory 218. For example, theadapter card 220 may recognize a data condition within the non-volatilememory 218 that produces sub-optimal printing conditions, and inresponse to this the adapter card 220 may replace some portions of thenon-volatile memory 218 with new data which improves printingperformance.

Thus, as shown in FIG. 10, this embodiment reads and writes to variousnon-volatile memory locations to enable closed loop control. The adaptercard 220 reads input or sensor non-volatile memory locations and usesthat data as feedback to make controlled adjustment to output oractuator non-volatile memory locations. This provides closed loopcontrol of the printing engine 210 without any system softwaremodification. Typical feedback type non-volatile memory locations cancontain, for example, data on temperature, RH, density readings,electrostatic voltage data, print count, etc. Typical actuator typenon-volatile memory 218 locations might contain grid voltage level, BCR(biased charging roll) AC current level, BCR DC voltage level,development bias, fuser lamp power, etc.

The adapter card 220 module can be added before the machine is deliveredto the customer or even after delivery, as a field upgrade kit,providing a method to read and write to important non-volatile memorylocations over the machine's life without any service engineerintervention.

Typical applications of the embodiment shown in FIG. 10 can includeadjustment of BCR DC voltage based on print count, using a differentalgorithm than the standard OEM algorithm; adjustment of BCR cleanerengagement rate based on print count to enable enhanced BCR life byminimizing abrasion related failures; reading temperature and RH datafrom non-volatile memory 218 and adjusting BCR Vpp (peak-to-peak ACvoltage) through non-volatile memory 218 to avoid LCM (lateral chargemigration) defects in certain environmental operating conditions (e.g.A-zone). This enables optimal (minimized) photoreceptor wear based onactual operating conditions (rather than forcing higher wear to avoiddefects that only occur in A-zone).

Note that the adapter card 220 enables implementation of a non-volatilememory 218-to-non-volatile memory 218 adjustment methodology that wasunforeseen at print engine development and manufacture time. Inaddition, the embodiments herein enable field upgrades of adjustmentalgorithms that may support optimized performance of a new customerreplaceable unit. For example the adaptor card could make adjustments toNVM locations corresponding to process control gains for existingcontrol algorithms in the system controller 216. By using the adaptercard 220, no print engine system software needs to be modified.

In another embodiment, shown in FIG. 11, the adapter card 220 storesdata and receives sensor feedback from the existing sensors 254. Theadapter card 220 uses the data and the sensor feedback to control theexisting actuators 252 by bypassing the engine controller 216 whencommunicating with the actuators. The adapter card 220 also providesadapter card 220 feedback to the non-volatile memory 218.

Therefore, with the embodiments shown in FIG. 11, the adapter card 220adjusts the values within the non-volatile memory 218 based on feedbackfrom the sensors 254 within the printing engine 210. This also allowsthe adapter card 220 to adjust the existing actuators 252 so as toimprove printing performance.

As shown in FIG. 11, the adapter card 220 reads existing sensors withinthe machine and modifies control actuations that are generated by theexisting system controller for the printer. Using this approach thesystem software does not need to be modified, nor does it need toinherently support the desired alterations as part of its design, butvalue-add solutions which would typically require special systemsoftware can still be implemented. This embodiment focuses on the use ofsensors and actuators outside of non-volatile memory 218 and customerreplaceable units 212 settings. Although this is slightly more intrusivethan some of the other embodiments mentioned herein, in order to enableacquisition of the required hardware signals, the approach of thepresent embodiment also enables a great deal more capability in terms ofthe types of control algorithms that can be implemented. Further, thepresent embodiment uses existing sensors and actuators within theprinting engine 210, beyond the system non-volatile memory 218parameters, for enabling value-add control technology injections.

There are a number of ways that could be used to enable access to therequired sensor and actuator signals in the printer. For the sensorsignals, it would typically be possible to modify the existing wiringharness in the machine (e.g. double-crimping additional wires to theleads of the sensor). For the actuators, it is often critical to ensurethat the existing system controller still have access to these sameadjustment mechanisms. This can be achieved in a number of ways. Forexample, the adapter card 220 actuation can simply be added to theexisting system controller's actuation using a hardware summing circuit.This type of approach has been demonstrated in the past for use inmodifying the raster output scanner power setting as part of certainbanding compensation strategies.

Although the proposed control implementations do require some degree ofhardware modification to gain access to the desired sensor and actuatorsignals, these modifications would typically be relatively minor. Thesemodifications could easily be done as field-retrofits to existingmachines in the field, or just prior to shipment as part of the printingengine sourcing process. Such minor hardware modifications are simple incomparison to requiring changes to the system software for a printengine. The embodiments herein therefore implement a parallel controllerto the existing engine software, without requiring any modifications tothe printer's software. This add-on module provides the platform toenable a variety of value-add closed loop control technology injections.

In another embodiment, shown in FIG. 12, the printing engine 210comprises existing sensors 252, existing (first) actuators 254, andadditional (second) actuators 258. The first actuators 254 correspond toa design of the controller 216, and the second actuators 258 correspondto a design of the adapter card 220. The adapter card 220 stores dataand receives feedback from the sensors. The adapter card 220 uses suchdata and the feedback to control the actuators 254, 258 by bypassing theengine controller 216 when communicating with the actuators 254, 258. Aswould be understood by one ordinarily skilled in the art, the adaptercard 220 can adjust the actuators 254, 258 in conjunction with inputfrom the existing system controller 216 or completely separately fromthe existing system controller 216.

The adapter card 220 also directly actuates the new additional engineactuators. The printing apparatus 200 is physically modified to mountthe adapter card 220 and new additional actuators 258 as well as to wirethe adapter card 220 to non-volatile memory 218 through the enginecontroller, to new additional actuators 258 and to existing sensors 252.

Printing machines retrofitted with an adapter card 220 and newadditional actuators 258 enable deployment of new technologies to thefield for improved machine performance with no upgrade of the systemsoftware required. In addition, there is no special requirement on thesystem software to support this upgrade functionality. In many cases theadapter card 220 actuates the new additional actuators 258 independentlyof the machine controller 216. In some cases the new additionalactuators 258 may need to be actuated in concert with existing machineactuators 254. In these cases the existing actuators 254 can be actuatedby modifying non-volatile memory 218 locations. Alternatively, theexisting actuators 254 can be wired to the adapter card 220. Mostengines already support adjustment of the non-volatile memory 218settings through at least one interface with the external world. Thepresent embodiment places a smart box (the adapter card 220) within theprinting engine 200 to enable such non-volatile memory 218 upgradeswithout any required contact with the external world. The systemsoftware does not need to be changed to enable the adapter card 220.

The adapter card 220 provides a feasible path for retrofitting newadditional actuators into existing engines to enable significantupgrades in engine performance. Without the adapter card 220,implementation of engine control changes requiring new additionalactuators have proven to be very difficult. The adapter card 220 removesthis barrier to improved engine performance through delivery ofvalue-add technology injections.

In an additional embodiment, shown in FIG. 13, the adapter card 220reads incoming print jobs before the print jobs are delivered to thecontroller 216 and the adapter card 220 uses the print jobs to adjustthe actuators either independently or in coordination with instructionsfrom the engine controller 216. Again, the incoming job stream is passedto the existing system controller 216 without modification as anunmodified job stream, as illustrated in FIG. 13. This embodimentpermits corrected direct adjustment of the existing actuators 252 whichbypasses the existing system controller 216. More specifically, theadapter card 220, permits alteration of the existing actuators 252without complicated and expensive modifications to the printer'ssoftware.

In the embodiments herein, the adapter card 220 comprises a physicallyseparate device from the engine controller 216. More specifically, theadapter card 220 can comprise, for example, a printed circuit board atleast one logic unit mounted on the printed circuit board, wiring withinthe printed circuit board connected to the logic unit, and connectionterminals on the printed circuit board connected to the wiring. Theconnection terminals can be operatively connected to the non-volatilememory 218, the existing actuators 252, the existing sensors 254, theadditional sensors 256, the additional actuators 258, the customerreplaceable units 212, etc. The adapter card 220 can be connected tosuch elements through one of the following interfaces: TCP/IP based webserver interface; front panel keyboard wedge interface; serviceinterface; direct hardwired connection; etc. Further, the adapter card220 comprises an item designed to be installed in the printing deviceafter the printing device is in post production, customer service.

The adapter card 220 is an inexpensive add-on board that provides acommunication vehicle between the engine controller and the othercomponents within the printing engine 210. The adapter card 220 reads aset of memory locations on the customer replaceable units 212, oftenthrough a radio frequency identification (RFID) interface, and modifiesnon-volatile memory 218 locations within the engine controller(potentially via TCP/IP, serial communication, front panel keyboardwedge, or direct connection) based on this information. Typically, theengine controller has the capability, as delivered from its manufacturerto modify non-volatile memory 218 by these protocols to enable theportable workstation software (PWS) that is used by the serviceengineers.

The adapter card 220 provides similar capability, without serviceengineer intervention or contact with the external world (i.e. networkupgrade). When a cartridge 212/214 is installed into the machine, theadapter card 220 reads pre-defined memory locations that contain anon-volatile memory 218 location to modify and the new value to write tothat location. The adapter card 220 then modifies values that reside inthe non-volatile memory 218 within the engine controller so that thecontroller can modify the control algorithms based on the newnon-volatile memory settings. This process is repeated every time a newcustomer replaceable unit is installed which provides a method ofmodifying the process control settings on a cartridge by cartridge basiswithout any service engineer intervention.

Such automated processing enables deployment of new technologies to thefield in the customer replaceable units with no upgrade of the systemsoftware required. In addition, there is no special requirement on thesystem software to support this upgraded functionality and/or technologysets within the customer replaceable units. Most engines already supportadjustment of the non-volatile memory settings through at least oneinterface with the external world. The present invention places a smartbox (the adapter card 220) within the printing device to enable suchnon-volatile memory upgrades without any required contact with theexternal world. The system software does not need to be changed toenable the adapter card 220.

The adapter card 220 module can be added before the machine is deliveredto the customer or even after delivery, as a field upgrade kit,providing a method to modify control settings and enable integration ofhardware and materials changes that occur over the machine's lifewithout any service engineer intervention. The adapter card also allowsmany different configurations of cartridge hardware to exist in thefield at the same time, since each cartridge modifies machinenon-volatile memory 218 regardless of what software version is loaded onthe machine. The following is an example of the impact of the adaptercard 220.

One hardware modification that can enable a reduction in run cost is thedevelopment of an overcoated photoreceptor. The photoreceptor has a 2-6micrometer coating as the top layer which prevents wear and scratchesthat occur during the contact charging process in these machines.Typical photoreceptor wear for current devices is around 30 nanometersper thousand cycles, while the overcoat has shown to have 2-3 nanometersper thousand cycles. This enables a 3-4× improvement in the life of thecustomer replaceable units for the color stations. The machines in thefield are designed to adjust the setpoints based on the thickness of thephotoreceptor transport layer. The manufacturer develops an algorithmfor these setpoint adjustments based on the wear rate of thephotoreceptor that ships with the machine. In order to use a cartridgewith the new overcoated photoreceptor, machine non-volatile memoriesneed to be modified to account for the much lower wear rate of theovercoat. Prior to embodiments herein, this would have been done by aservice call to modify the non-volatile memory 218 or download newsoftware to the machine. This non-volatile memory change (service call)would be needed every time the customer switched from one type ofphotoreceptor to the other, making introduction of the over-coatedphotoreceptor a logistical nightmare to implement in the field.

However, with the adapter card 220 module installed in the machine, theadapter card 220 uses the customer replaceable units 212, often throughan RFID interface, in the replaceable photoreceptor unit to determinewhich photoreceptor resides in that particular cartridge. The customerreplaceable units 212 contains the non-volatile memory locations and thenew non-volatile memory values, which the adapter card 220 reads, oftenthrough an RFID interface, and makes the required modifications to themachines non-volatile memory 218 to accommodate that particularphotoreceptor device. This is done using the current TCP/IP, front panelkeyboard wedge, direct connection, or serial port 240 that alreadyexists on most engine controllers. In this case, the non-volatile memorylocations that contain the coefficients for the setpoints that changebased on photoreceptor wear are modified to provide the correctadjustments for the overcoated device. The adapter card 220 is used todetermine which photoreceptor is in the cartridge and modifies themachine engine controller accordingly, every time the customer installsa new cartridge. This enables multiple cartridge configurations toexist, simultaneously, in the field. While the photoreceptor was used inthis example, the concept can be used for any subsystem or device in theprint engine 200.

The adapter card 220 enables hands-free modification of the machinecontroller, on a cartridge-by-cartridge basis, to allow for run cost orcustomer satisfaction improvements that occur over the product'slifetime. This allows the needed “hooks” in the machine architecturethat outsourcing manufacturers do not enable when the machine islaunched and provides a method of implementing improvements withoutcostly field upgrades for each improvement initiative.

The embodiments herein enable the seamless deployment of value-addtechnologies into print engines for which one does not have directcontrol over the system software. Automated management of thenon-volatile memory settings based on the customer replaceable unitsparameters enables non-volatile memory adjustment on a per-cartridgebasis (thereby allowing cartridges of mixed technologies to be in thefield at any given time without issue). While non-volatile memoryadjustments could be made using an external interface, a technicalrepresentative, service engineer, or remote connection directly to themachine, these other methods do not provide the easy, automatedcapability to immediately adjust parameters as needed based on thespecific device (and its customer replaceable units 212) that isinstalled into the machine. Additionally, these other options all add tothe post sale service cost of the print engine.

Many items within a printing engine, such as actuators, are discussedabove. These actuators can include items that move physically, such assolenoids, etc., and can also include electro-photographic actuators.Each marking technology is associated with different marking technologyactuators. Electro-photographic actuators include items such as thecoronode voltage and the grid voltage of the electro-photographicmarking engine. Electro-photographic systems include various levels ofcontrol loops for maintaining the electro-photographic actuators at setpoints.

For example, an electro-photographic marking engine may include acharging element, an exposure element, a developer, and a fuser, whicheach can be associated with one or more electro-photographic actuators.The charging element may be a corotron, a scorotron, or a dicorotron. Ineach of these devices, a voltage is applied to a coronode (wire or pins)to ionize surrounding air molecules, which in turn causes a charge to beapplied to a photoconductive belt or drum. Where the charging element isa scorotron, the scorotron includes a grid, to which a grid voltage isapplied. The scorotron grid is located between the coronode and thephotoconductor and helps to control the charge strength and uniformityof the charge applied to the photoconductor. The coronode voltage andthe grid voltage are electro-photographic actuators. Changing eithervoltage may result in a change in the charge applied to thephotoconductor, which in turn may affect an amount of toner attracted tothe photoconductor and therefore the lightness or darkness of a printedor rendered image. Many electro-photographic marking engines include oneor more electrostatic volt meters (ESV) for measuring the charge appliedto the photoconductor. In such systems, a control loop receivesinformation from the ESV and adjusts one or both of the coronode voltageand the grid voltage in order to maintain a desired ESV measurement. SeeU.S. Pat. No. 7,593,130 (the complete disclosure of which isincorporated herein) and the disclosures mentioned therein for a morecomplete description of electro-photographic actuators.

While only a few actuators are discussed above, those ordinarily skilledin the art would understand that many other actuators could be used withembodiments herein and the term “actuators” as used herein includes allsuch meanings.

Many computerized devices are discussed above. Computerized devices thatinclude chip-based central processing units (CPU's), input/outputdevices (including graphic user interfaces (GUI), memories, comparators,processors, etc. are well-known and readily available devices producedby manufacturers such as Dell Computers, Round Rock Tex., USA and AppleComputer Co., Cupertino Calif., USA. Such computerized devices commonlyinclude input/output devices, power supplies, processors, electronicstorage memories, wiring, etc., the details of which are omittedherefrom to allow the reader to focus on the salient aspects of theembodiments described herein. Similarly, scanners and other similarperipheral equipment are available from Xerox Corporation, Norwalk,Conn., USA and the details of such devices are not discussed herein forpurposes of brevity and reader focus.

The terms printer or printing device as used herein encompasses anyapparatus, such as a digital copier, bookmaking machine, facsimilemachine, multi-function machine, etc., which performs a print outputtingfunction for any purpose. The details of printers, printing engines,etc., are well-known by those ordinarily skilled in the art and arediscussed in, for example, U.S. Pat. No. 6,032,004, the completedisclosure of which is fully incorporated herein by reference. Theembodiments herein can encompass embodiments that print in color,monochrome, or handle color or monochrome image data. All foregoingembodiments are specifically applicable to electrostatographic and/orxerographic machines and/or processes.

It will be appreciated that the above-disclosed and other features andfunctions, or alternatives thereof, may be desirably combined into manyother different systems or applications. Various presently unforeseen orunanticipated alternatives, modifications, variations, or improvementstherein may be subsequently made by those skilled in the art which arealso intended to be encompassed by the following claims. The claims canencompass embodiments in hardware, software, and/or a combinationthereof. Unless specifically defined in a specific claim itself, stepsor components of the embodiments herein cannot be implied or importedfrom any above example as limitations to any particular order, number,position, size, shape, angle, color, or material.

What is claimed is:
 1. A printing device comprising: at least oneprinting engine comprising actuators, first sensors, and second sensors;at least one engine controller operatively connected to said printingengine, said engine controller using software to control operations ofsaid printing engine; at least one non-volatile memory operativelyconnected to said engine controller, said non-volatile memory storingvalues used by said engine controller to control operations of saidprinting engine; and at least one adapter card operatively connected tosaid non-volatile memory and to said first sensors and second sensors,said adapter card comprising: a physically separate device from saidengine controller; a printed circuit board; at least one logic unitmounted on said printed circuit board; wiring within said printedcircuit board connected to said logic unit; and connection terminals onsaid printed circuit board connected to said wiring, said connectionterminals being operatively connected to said non-volatile memory, saidfirst sensors corresponding to a design of said engine controller, saidsecond sensors corresponding to a design of said adapter card, saidadapter card receiving feedback from said first sensors and said secondsensors, said adapter card reading incoming print jobs, said adaptercard using said incoming print jobs and said feedback from said firstsensors and said second sensors to control said actuators by bypassingsaid engine controller when communicating with said actuators.
 2. Theprinting device according to claim 1, said adapter card being connectedto said non-volatile memory through one of the following interfaces:TCP/IP based web server interface; front panel keyboard wedge interface;service interface; print job submission interface; and direct hardwiredconnection.
 3. The printing device according to claim 1, said adaptercard comprising an item designed to be installed in said printing deviceafter said printing device is in post production, customer service. 4.The printing device according to claim 1, said adapter card providingadapter card feedback to said non-volatile memory.
 5. A printing devicecomprising: at least one printing engine comprising actuators, firstsensors, and second sensors; at least one engine controller operativelyconnected to said printing engine, said engine controller using softwareto control operations of said printing engine; at least one non-volatilememory operatively connected to said engine controller, saidnon-volatile memory storing values used by said engine controller tocontrol operations of said printing engine; and at least one adaptercard operatively connected to said non-volatile memory and to said firstsensors and second sensors, said adapter card comprising: a physicallyseparate device from said engine controller; a printed circuit board; atleast one logic unit mounted on said printed circuit board; wiringwithin said printed circuit board connected to said logic unit; andconnection terminals on said printed circuit board connected to saidwiring, said connection terminals being operatively connected to saidnon-volatile memory, said first sensors corresponding to a design ofsaid engine controller and comprising items designed as originalequipment of said printing device, said second sensors corresponding toa design of said adapter card and comprising items designed to beinstalled in said printing device after said printing device is in postproduction, customer service, said adapter card receiving feedback fromsaid first sensors and said second sensors, said adapter card using saidfeedback from said first sensors and said second sensors to control saidactuators by bypassing said engine controller when communicating withsaid actuators.
 6. The printing device according to claim 5, saidadapter card being connected to said non-volatile memory through one ofthe following interfaces: TCP/IP based web server interface; front panelkeyboard wedge interface; service interface; print job submissioninterface; and direct hardwired connection.
 7. The printing deviceaccording to claim 5, said adapter card comprising an item designed tobe installed in said printing device after said printing device is inpost production, customer service.
 8. The printing device according toclaim 5, said adapter card providing adapter card feedback to saidnon-volatile memory.
 9. A printing device comprising: at least oneprinting engine comprising actuators, first sensors, and second sensors;at least one engine controller operatively connected to said printingengine, said engine controller using software to control operations ofsaid printing engine; at least one non-volatile memory operativelyconnected to said engine controller, said non-volatile memory storingvalues used by said engine controller to control operations of saidprinting engine; and at least one adapter card operatively connected tosaid non-volatile memory, said actuators, said first sensors, and saidsecond sensors, said adapter card comprising: a physically separatedevice from said engine controller; a printed circuit board; at leastone logic unit mounted on said printed circuit board; wiring within saidprinted circuit board connected to said logic unit; and connectionterminals on said printed circuit board connected to said wiring, saidconnection terminals being operatively connected to said non-volatilememory, said first sensors corresponding to a design of said enginecontroller, said second sensors corresponding to a design of saidadapter card, said adapter card storing data and receiving sensorfeedback from said second sensors, said adapter card using said data andsaid sensor feedback to control said actuators by bypassing said enginecontroller when communicating with said actuators, and said adapter cardproviding adapter card feedback to said non-volatile memory.
 10. Theprinting device according to claim 9, said adapter card being connectedto said non-volatile memory through one of the following interfaces:TCP/IP based web server interface; front panel keyboard wedge interface;service interface; print job submission interface; and direct hardwiredconnection.
 11. The printing device according to claim 9, said adaptercard comprising an item designed to be installed in said printing deviceafter said printing device is in post production, customer service. 12.A printing device comprising: at least one printing engine comprisingactuators, first sensors, and second sensors; at least one enginecontroller operatively connected to said printing engine, said enginecontroller using software to control operations of said printing engine;at least one non-volatile memory operatively connected to said enginecontroller, said non-volatile memory storing values used by said enginecontroller to control operations of said printing engine; and at leastone adapter card operatively connected to said non-volatile memory, saidactuators, said first sensors, and said second sensors, said adaptercard comprising: a physically separate device from said enginecontroller; a printed circuit board; at least one logic unit mounted onsaid printed circuit board; wiring within said printed circuit boardconnected to said logic unit; and connection terminals on said printedcircuit board connected to said wiring, said connection terminals beingoperatively connected to said non-volatile memory, said first sensorsand said actuators corresponding to a design of said engine controllerand comprising items designed as original equipment of said printingdevice, said second sensors corresponding to a design of said adaptercard and comprising items designed to be installed in said printingdevice after said printing device is in post production, customerservice, said adapter card storing data and receiving sensor feedbackfrom said second sensors, said adapter card using said data and saidsensor feedback to control said actuators by bypassing said enginecontroller when communicating with said actuators, and said adapter cardproviding adapter card feedback to said non-volatile memory.
 13. Theprinting device according to claim 12, said adapter card being connectedto said non-volatile memory through one of the following interfaces:TCP/IP based web server interface; front panel keyboard wedge interface;service interface; print job submission interface; and direct hardwiredconnection.
 14. The printing device according to claim 12, said adaptercard comprising an item designed to be installed in said printing deviceafter said printing device is in post production, customer service.